DEPARTMENT OF CIVIL ENGINEERING

PONDICHERRY ENGINEERING COLLEGE

PONDICHERRY – 605014

BACHELOR OF TECHNOLOGY

CIVIL ENGINEERING

(VII SEMESTER)

IN-PLANT TRAINING REPORT

Submitted by

G. INDUMATHI

REG NO: 283175060

PONDICHERRY UNIVERSITY

PONDICHERRY

OCTOBER 2010

CONTENTS:

1. JENO MARAN CONSTRUCTIONS PVT LIMITED, PUDUCHERRY

2. LARSEN & TOURBO ENGINEERING CONSTRUCTION AND CONTRACTS DIVISION- FORMWORK FACTORY

3. PUBLIC WORKS DEPARTMENT, PUDUCHERRY

55,KAMATCHI AMMAN KOVIL STREET, PUDUCHERRY

CONTENTS:

Thirumala RMC Plant, Puducherry Post Tensioning Beam at Lakshmi Mahal, Eripakkam,

Puducherry Pile Foundation at Jeno Galaxy Apartment , Krishna Nagar,

Puducherry Lectures on Auto-CAD, STAAD PRO, Estimation , Costing and

Valuation

Thirumala RMC PLANT, Kurumampet

Data collected:

Design mix data:

Grade of concrete M30

Specific gravity of fine aggregate 2.67

Specific gravity of coarse aggregate(20mm) 2.78

Specific gravity of coarse aggregate(12mm) 2.77

Degree of control Good

Type of exposure Moderate

Maximum size of aggregate 20mm

Type of cement OPC 43

Advantages of site mixed concrete and ready mix concrete:

ITEM SITE MIXED

CONCRETE

RMC

Raw material Required near mixer At batching plant

Weighing Manual Computerized

Moisture adjustment Approximate Automatic

Water cement ratio Manual Approximate Computerized

Dozing of admixture Manual Approximate Computerized

Mixing Tilting mixer Pan mixer

Mixing time Approximate Auto timer

Batch size 140litre 500litre

Discharge Platform Transit mixer pump

Rate of concrete 3m3/hr/mixer 30m3/hr/plant

QUALITY

Degree of control Fair Excellent

Cement 380Kg

Water 160kg

fine aggregate 690kg

Coarse aggregate(20mm) 850kg

Coarse aggregate(12mm) 360kg

Admixture (Fosroc) 3liters

Yield Variable Consistent

Testing fresh concrete Once in 25 batches Every batch

RAW MATERIALS

Selection /sourcing Client /contractor RMC experts

Testing Client /contractor RMC experts

Storage Multi location Single place

Space requirement Large Limited area

DELIVERY Manual Transit mixer

PLACING:

Mode Manual/hoist/crane Concrete pump

Rate 3m3/hr As per requirement

POST TENSIONING BEAM AT LAKSHMI MAHAL

Pre-tensioning and post-tensioning are the two forms of pre-stressing. Prestressed concrete is a method for overcoming concrete's natural weakness in tension. It can be used to produce beams, floors or bridges with longer span  with ordinary reinforced concrete.

In this site, the hall is constructed without intermediate columns and the loads are transmitted to the edge columns. So the method of post-tensioning is adopted after concrete hardens.

EQUIPMENTS:

Tendons (a group of pre-stressing cables), Hydraulic jack (monojack) of 25 tons capacity, the cables are inserted through the wedge block placed on duct provided with a given profile.

LOAD APPLIED:

The ultimate load of the cable is 180 kN/m2

But only 75% load is applied.

Stress= (Load/area) *jack loss

Ramp area of the jack =37.09cm2

Jack loss=2%

Stress= (186X1000X0.75X1.02)/ (37.09X102) =38.36 N/mm2

Therefore load to be applied to the cables =39KN

At one edge of the beam, the duct is provided and the prestressed and the other end is called the dead end of bulb end. At the dead end, the tendons will be stretched like a flower to prevent the tendons to enter back due to tension.

PROCEDURE:

1. Concrete cube testing is done here to obtain strength of 26N/mm2 before tensioning.2. Initial load of 100 bar pressure is given to the rods to release the twisted of moved

tendons inside beams.3. Marking is done from the casting.4. Then 39kN load is given to the cables through monojack and the elongation is

observed i.e. distance from the casting to the outside.5. Grouting: It is done for filling gaps on the beam by using a paste of Ordinary Portland

Cement slurry+ cornplast are used.

PILE FOUNDATION AT JENO GALAXY APARTMENT

From geo-technical report, 46 columns have to be constructed in this site for an apartment building. A hard stratum is found to be 25 feet. The soil investigation conducted in this site recommends the construction of pile foundation since clay soil is found.

FOUNDATION DETAILS:

Depth of pile- 7.92m (26feet)

Diameter of rings-0.3m (1 foot)

Cover on both sides-0.45m (1feet 6inches)

Quick setting cement is used-for this a quick setting admixture called concare of 125ml is added to 25kg of cement.

Reinforcement Details:

The main reinforcement: 12mm

Secondary reinforcements: 8mm diameter.

Secondary reinforcement of ring type with cover: 45mm.

Diameter of steel rod in pile-12mm

Spacing of rings-a) bottom to top (for 23 feet)-0.2m

b) last 3feet -0.15m

For 9’’X1’ ½’’ columns( 6 no’s)- triple pile of 1.25feet diameter is to be provided For 9’’X9’’ columns (39 no’s)-double pile of 1.25 feet diameter is to be used. For 9’’X9’’ column (1 no)-single pile of 1.5feet diameter is to be used.

Placing of reinforcements:

1. The reinforcements was placed inside the casing before concreting the casing .The prepared reinforcements was taken and placed inside the casing using hook.

2. The provided cover block helps to maintain the cover distance and provides the rigidity to the reinforcement all along the length of casing.

3. The prepared reinforcement is placed in position as shown in figure. 4. After placing the reinforcements, it is held in position till concreting the casing.

Casing details:

CASING HEIGHTLarge casing 2.1mSmall casing 8.3mAUGER DIAMETERLarge auger 0.43m

Small auger 0.38m

LARSEN AND TOUBRO –ENGINEERING CONSTRUCTION

AND CONTRACTS DIVISION

FORMWORK FACTORY, SEDARAPET,

PUDUCHERRY.

INTRODUCTION:

In the training programme of six days, I learnt the Planning, Production and Despatch of Formworks and scaffolds using Steel, Aluminium and Timber in L&T-E.C.C-Formwork factory.

L&T Formwork Business Unit, offers “Total Formwork Solutions” for all types of reinforced concrete structures for varied applications.  Formwork gives form or shape to concrete and also it supports the weight of concrete until it attains sufficient strength to carry its own weight and it ensures speedy construction with high levels of accuracy and superlative concrete finish together with enhanced productivity.

FORMWORK AND SCAFFOLDS:

Formwork is a mould used for the construction of concrete beams, columns and walls.

Scaffold is used for safe construction considering the safety of labourers, for climbing and working.

PLANNING:

This is the common process in the manufacture of formworks. It involves order booking, getting raw materials, obtaining design,schedule and despatch. Constant follow-up is done to make the work according to scheduled time.

PRODUCTION OF STEEL FORMWORK:

1. Cutting the steel pipes or rods of desired length (using band saw).

2. Punching holes in them(using drilling machine)3. Threading the pipes4. Bending of steel plates5. After making the required shape, the components are painted.

PAINTING OF STEEL COMPONENTS:

Degreasing of components water rinsing derusting water rinsing phospating using zinc air drying paint dipping paint dryer.

Since dipped in paint, the whole component gets protected from environmental conditions.

Before painting, welding of joints is done by Metal Active Gas(MAG) welding, carbon di oxide is used. There is no formation of flux.

SYSTEMS USED IN STEEL FORMWORK:

Mock-ups for beam, column and wall are made of steel and timber. These include Flex system, Beam forming system, Wall column system, Access scaffold system, Climbing scaffold, Heavy duty tower system.

FLEX SYSTEM

QUALITY ASSURANCE AND CONTROL:

Different tests are done on the components of formwork both physical and chemical test namely Hardness test, Finding different values of threader pipe using Profile projector.

Chemical analysis involves using Spectrometer to find 19elements in steel including carbon content by wet analysis for accurate value.

Costing of formwork:

Cost of material per use=(cost of materials-scrap value)/number of repetitions

Cost of material for an item in the project=(cost of material-(scrap value

*period of use))/life of material

PRODUCTION OF ALUMINIUM AND TIMBER FORMWORK:

There are 12 systems of timber formworks used here which are composed of H-beams made of plywood and timber. The timber used

WALL AND COLUMN SYSTEM

here are spruce and rubber wood which are the plantation timber recommended by the Government for use. The h-beams are of size H-16 and H-20.

The timber is seasoned and treated to reduce the moisture content from 6 to 12%.

DEFECTS IN TIMBER:

The defects in timber were observed in the timber workshop of L&T formwork factory which are us follows, the seasoning and treatment of timber reduces these defects and the H-beams are produced

H-BEAMS MADE OF TIMBER AND

PLYWOOD

BROKEN TAPPING MARKS

PRODUCTION PROCEDURE:

1. Timber and plywood are cut ,where they have defects,to required length.

2. Finger jointing is done and the timber pieces are joined using Phenol Resorcinol Formaldehyde resin(PRF).

3. The timber is checked whether it is treated .4. Same procedure is done for plywood5. Timber and plywood are joined as H-beam using Beam

press machine6. Painting is done by spraying7. Testing is done for tensile strength,flexure strength

TIMBER CRACKS

ALUMINIUM FORMWORK:

Aluminium used here is an alloy of magnesium. The three systems produced here are a) aluminium frame with plywood sheathing,b)Aluminium frame with aluminium sheathing,c) aluminium frame with plastic sheathing.

SAFETY MEASURES IN FACTORY:

1.Treatment of Effluents:

Bio-assay test is done to reduce the acidity of effluents from formwork factory of pH 3to 10 and 11 of alkalinity.

Effluents in reaction tank settling tank sludge removal collection tank(pH 7.5 to 8.5),effluent treated trade water used for growing plants air receiver

2. Hcl Scrubber:

The gases coming out from the painting process are sent into atmosphere after neutralizing them using NaOH(caustic soda),the pollution control board approved 70 mg ,but only 0.67 mg is let out.

TESTING OF H-BEAMS

LARSEN AND TOUBRO –ENGINEERING CONSTRUCTION

AND CONTRACTS DIVISION

FORMWORK FACTORY, SEDARAPET,

PUDUCHERRY.

INTRODUCTION:

In the training programme of six days, I learnt the Planning, Production and Despatch of Formworks and scaffolds using Steel, Aluminium and Timber in L&T-E.C.C-Formwork factory.

L&T Formwork Business Unit, offers “Total Formwork Solutions” for all types of reinforced concrete structures for varied applications.  Formwork gives form or shape to concrete and also it supports the weight of concrete until it attains sufficient strength to carry its own weight and it ensures speedy construction with high levels of accuracy and superlative concrete finish together with enhanced productivity.

FORMWORK AND SCAFFOLDS:

Formwork is a mould used for the construction of concrete beams, columns and walls.

Scaffold is used for safe construction considering the safety of labourers, for climbing and working.

PLANNING:

This is the common process in the manufacture of formworks. It involves order booking, getting raw materials, obtaining design,schedule and despatch. Constant follow-up is done to make the work according to scheduled time.

PRODUCTION OF STEEL FORMWORK:

1. Timber and plywood are cut ,where they have defects,to required length.

2. Finger jointing is done and the timber pieces are joined using Phenol Resorcinol Formaldehyde resin(PRF).

3. The timber is checked whether it is treated .4. Same procedure is done for plywood

5. Timber and plywood are joined as H-beam using Beam press machine

6. Cutting the steel pipes or rods of desired length (using band saw).

7. Punching holes in them(using drilling machine)8. Threading the pipes9. Bending of steel plates10. After making the required shape, the components are

painted.

PAINTING OF STEEL COMPONENTS:

Degreasing of components water rinsing derusting water rinsing phospating using zinc air drying paint dipping paint dryer.

Since dipped in paint, the whole component gets protected from environmental conditions.

Before painting, welding of joints is done by Metal Active Gas(MAG) welding, carbon di oxide is used. There is no formation of flux.

SYSTEMS USED IN STEEL FORMWORK:

Mock-ups for beam, column and wall are made of steel and timber. These include Flex system, Beam forming system, Wall column system, Access scaffold system, Climbing scaffold, Heavy duty tower system.

QUALITY ASSURANCE AND CONTROL:

Different tests are done on the components of formwork both physical and chemical test namely Hardness test, Finding different values of threader pipe using Profile projector.

Chemical analysis involves using Spectrometer to find 19elements in steel including carbon content by wet analysis for accurate value.

FLEX SYSTEM

WALL AND COLUMN SYSTEM

Costing of formwork:

Cost of material per use=(cost of materials-scrap value)/number of repetitions

Cost of material for an item in the project=(cost of material-(scrap value *period of use))/life of material

PRODUCTION OF ALUMINIUM AND TIMBER FORMWORK:

There are 12 systems of timber formworks used here which are composed of H-beams made of plywood and timber. The timber used here are spruce and rubber wood which are the plantation timber recommended by the Government for use. The h-beams are of size H-16 and H-20.

The timber is seasoned and treated to reduce the moisture content from 6 to 12%.

DEFECTS IN TIMBER:

The defects in timber were observed in the timber workshop of L&T formwork factory which are us follows, the seasoning and treatment of timber reduces these defects and the H-beams are produced

H-BEAMS MADE OF TIMBER AND

PLYWOOD

BROKEN TAPPING MARKS

TIMBER CRACKS

PRODUCTION PROCEDURE:

1. Timber and plywood are cut ,where they have defects,to required length.

2. Finger jointing is done and the timber pieces are joined using Phenol Resorcinol Formaldehyde resin(PRF).

3. The timber is checked whether it is treated .4. Same procedure is done for plywood5. Timber and plywood are joined as H-beam using Beam

press machine6. Painting is done by spraying7. Testing is done for tensile strength,flexure strength

ALUMINIUM FORMWORK:

Aluminium used here is an alloy of magnesium. The three systems produced here are a) aluminium frame with plywood sheathing,b)Aluminium frame with aluminium sheathing,c) aluminium frame with plastic sheathing.

TESTING OF H-BEAMS

SAFETY MEASURES IN FACTORY:

1.Treatment of Effluents:

Bio-assay test is done to reduce the acidity of effluents from formwork factory of pH 3to 10 and 11 of alkalinity.

Effluents in reaction tank settling tank sludge removal collection tank(pH 7.5 to 8.5),effluent treated trade water used for growing plants air receiver

2. Hcl Scrubber:

The gases coming out from the painting process are sent into atmosphere after neutralizing them using NaOH(caustic soda),the pollution control board approved 70 mg ,but only 0.67 mg is let out.

PUBLIC WORKS DEPARTMENT

GOVERNMENT OF PUDUCHERRY

PUDUCHERRY

ESTIMATION OF A PLAN:

The detailed estimation is done based on the Pondicherry Schedule of Rates(PSR) for a Pump house plan. The quantities are arrived using a software used exclusively in P.W.D

TENDERING PRACTISE:

Preparation of preliminary estimate government order detailed technical estimate Notice Inviting Tender

CLASSES OF TENDERING:

1. Percentage rate tender(small projects) upto 5 lakhs.2. Item rate tender (5to 10 lakhs)3. Lumpsum tender(10lakhs to crores)4. Public-Private Partnership

E-TENDERING:

I attended the pre-bid meeting of the first project through e-tendering for the ‘BALANCE WORK OF CONSTRUCTION OF BRIDGE IN ARIYANKUPPAM’ in which they discussed on the details of the work to be completed, the construction work was stopped due to the sinking of pier-4and land acquisition problems on the approach roads of the bridge, the

balance work includes the pier-5, abutments, carriageway, retaining wall.

DETAILS: It’s a four-lane bridge across NH 45-A Span-6spans(2 abutments and 4 piers)

STAAD ANALYSIS:

Seismic analysis the pump house is carried out using STAAD Pro software licensed to P.W.D,Puducherry,based on IS 1893 for basic load cases and combination load cases and the analysis report is attached here